Portable mail sorting and consolodating method and machine

ABSTRACT

A machine and process for presenting consolidated groups or batches of mail of a common address from pre-sorted or D.P.S. Distribution Point Sequence mail or any other machine-readable and address-sorted mail to a mail carrier for delivery to said common address. Whereby a portable machine is used in the delivery carriers vehicle which the carrier loads with D.P.S. mail. The mail pieces are conveyed through the machine past a bar code reader and a scanner operatively connected to a microprocessor operatively connected to a video monitor which displays the images of the mail pieces addresses to the carrier for confirmation of correct delivery. The microprocessor uses the bar code to determine the number of mail pieces to be delivered to each address by comparing the bar codes as each mail piece is conveyed through the machine. All bar codes for a given address are the same so the microprocessor sends all of the mail pieces which have the same bar code through to to the delivery receptacle for delivery by the carrier. When a different bar code than the previous bar code is conveyed across the bar code scanner, the conveying process stops until the carrier removes the mail pieces which all have the same bar code and the same address for delivery. At this time the machine automatically restarts the process.

BACKGROUND

1. Field of Invention

This invention relates to carrying and delivering machine pre-sorted route ready mail.

2. Description of Prior Art

Currently D.P.S., Distribution Point Sequence, mail is sorted by a bar-code which is provided by the mailer or applied by the postal system. The bar-code contains information about each address which enables the post office to use automated sorting machines to sequence mail in route order for each delivery route. While this mail has been sorted by automated machines, when it gets to the delivery carrier, it has to be manually sorted through and separated and examined by the carrier before delivery to each address. This process when done manually is known as “fingering” the mail. Many carriers so abhor having to finger the pre-sorted mail on the route in their vehicle that they resort to casing this mail in the office into their sorting cases. While this lessens the burden of having to sort through two different bundles of mail on the route, cased mail and pre-sorted mail, it wastes time for the carrier to re-sort mail which is already sorted by route order. Also the delivery carriers who do take their pre-sorted D.P.S. mail to the street sometimes resort to fingering this mail as they drive, taking their attention away from the task at hand, driving safely. Having machine ready mail for delivery to each address would add productivity and reduce the amount of time each carrier spent out on the route, which would require less running time per delivery, which would in turn reduce fuel consumption of their delivery vehicle.

OBJECTS AND ADVANTAGES

Accordingly, besides the objects and advantages of the machine and method described in my above patent, several objects and advantages of the present invention are:

-   -   a. less physical handling of mail pieces by the delivery         carrier, resulting in more efficiency and speedier delivery with         less physical strain of the delivery carrier.     -   b. more accurate delivery of mail pieces due to easier method of         affirming mail addresses     -   c. less time used per delivery by delivery carrier resulting in         savings in cost per delivery address.     -   d. less time used per delivery means delivery vehicle spends         less time running per delivery, resulting in fuel savings.

DRAWING FIGURES

FIG. 1 is a perspective drawing representative of the machine containing the following parts.

-   10 Outer protective and esthetic cover -   12 Mail receiving receptacle -   14 Mail delivery receptacle -   16 L.C.D. or video or functional equivalent monitor -   18 Console incorporating a keyboard function, switches, and function     lights -   20 Externally mounted removable bar code scanner with wireless blue     tooth type information relay system -   24 External computer input and download port

FIG. 2 is a side view representative of the main inner parts.

-   26 Downward pressure arm -   28 G.P.S. Global Positioning System -   30 A, B, and C non-slip pad or strips -   32 Base and frame -   34 Optical sensor -   36 Mail conveyors with floating belt -   36 a Pulley -   36 b Roller -   36 c Roller -   36 d Roller -   36 e Roller -   36 f Roller -   36 g Roller -   36 h Roller -   36 i Mail conveying belt or belts -   36 j Mail conveying belt or belts -   36 k Pulley -   36 l Pick roller drive belt -   38 Main drive belt -   40 Idler pulley     -   42 Drive pulley     -   44 Motor     -   46 Solenoid activated pick roller     -   48 Separator pad     -   50 Separator pad     -   52 Image capturing device reader and bar code reader or device         which combines both functions -   54 Internal power supply -   56 Computer or microprocessor programmable

FIG. 3 is a representative view of the mail and features intended to be handled by the machine

-   60 Typical letter -   62 Typical address -   64 Typical bar code

FIG. 4 is a flow chart showing the process.

Not shown in drawings are power cords, transformers, cooling fans, all wiring, relays, switches, fuses, circuit breakers and attendant hardware for function as well as computer programs for microprocessor and G.P.S. units, as these items are well known by those skilled in the art of this

SUMMARY

A machine for presenting mail to delivery carrier for each delivery address from pre-sorted mail pieces.

DESCRIPTION

The machine described as follows consists of a base 32 with non-slip pads or strips 30 a, b, and c mounted on the bottom. Containing a chassis, not shown in drawings, to hold an outer protective and esthetic cover 10. To incorporate a mail receiving receptacle 12 with a downward pressure arm 26 and an optical sensor 22. A mail delivery receptacle 14. An L.C.D. or video or functional equivalent monitor 16. A console incorporating a keyboard function, switches, and function or warning lights 18. An external computer input and download port 24. An externally mounted removable bar-code scanner with wireless blue-tooth type information relay system 20 for scanning accountable mail such as certified and registered mail. Removable or hinged access provisions and interior mounted cooling and dust exhausting fans, not shown in drawings. An external power cord for 12-volt vehicle accessory plug, not shown in drawings, mounted at the bottom of the receiving chute. A solenoid activated pick roller 46 and a separator roller 50 and a separator pad 48. Inside the housing is mounted a image capturing scanner and a bar code reader or device which combines both functions 52. A mail conveying system consisting of belts and rollers or the functional equivalent 36, 36 a, 36 b, 36 c, 36 d, 36 e, 36 f, 36 g, 36 h, 36 i, 36 j, 36 k and 36 l. A motor 44 and a drive mechanism 38. A computer or a microprocessor, programmable, 56. A power source internal 54. All wiring, relays, switches, transformers, fuses, circuit breakers, and attendant hardware for function, not shown in drawings. The machine would be powered by a 12-volt vehicle accessory plug, not shown in drawings, and or by a self-contained rechargeable battery 54 and have data access plugs for uploads and downloads 24 and a 110-volt AC cord for use in office, not shown in drawings. The outer cover should be made of high-impact plastic and or metal or similar materials 10 and be hinged in strategic locations, not shown in drawings, to enable cleaning and maintenance or fixing jams. A small fan or fans would expel paper dust and other debris and cool the computer, not shown in drawings. A console convenient to the carrier which would contain the power switch and a low- or no-mail warning light. A carrier initiated control to cause conveyor to shuttle mail through the machine 18 to enable clearing jams. On-screen prompts would be used to warn carrier of non-delivery addresses. A keyboard contained in the console 18 which would be used by the carrier to program prompts to be displayed on screen such as the name or names of the customer at each address, or a prompt to notify if a customers mail is on hold or is to be forwarded, thus not to be delivered. A route description function would be incorporated, which could be downloaded from another computer or entered by the keyboard, which would display on-screen prompts and direction of travel to notify the carrier where next to turn or go straight from the last customers address to help new or substitute carriers more easily follow routes which are new to them. Alternatively, a G.P.S. function 54 could be used to do the same and help the post office track the carriers progress. Also some mailers are starting to want confirmation of date of delivery for their mailing. This information would be stored or downloaded to an online office computer.

The components and assembly are well known by those who are skilled in the art of the above mentioned invention. In addition the programming skills necessary for function of the computer, microprocessor, and G.P.S. units are well known by those skilled in the particular field. The machine may be made with fewer or more features or more or less complex and still serve the same functional method of separating the pre-sorted mail into deliverable groups or batches of mail to a common address for delivery to said common addresses. A machine which consolidates the mail for each separate delivery address into a single stack for delivery to said address without the necessity to finger through and examine each individual piece before delivery to a single address. This is my current best mode of operation for this machine but it can be easily appreciated that the machine could serve its basic function with more or fewer parts or substitute parts such as no internal power source or no external scanner function and even no monitor or keyboard for basic function or a different mail conveying system or no input or download ports or function or no addition of a G.P.S., Global Positioning System, for the route travel information.

Operation

In using my invention, the mail carrier would load D.P.S. pre-sorted mail typified by FIG. 3 into a receiving receptacle on the machine which would be equipped with a downward tensioning device and an optical sensor or photo cell which would activate a warning signal, a light, or on-screen prompt to notify the carrier when empty or low. The carrier would activate the machine via a console mounted switch. Then the mail would convey through the machine one piece at a time by means of a solenoid activated pick roller and belts and rollers powered by a motor connected by a belt or belts or by gears past a separator pad and a separator roller to insure separation of mail pieces over a wide angle optical character reader and bar code reader or a device which combines both functions to read the address bar code and transmit this information and the address image to a connected computer or microprocessor which reads the address bar code and relays the address image to the monitor and determines the machine operation by the appropriate wiring and relays. The bar code would be read and an image of the delivery address would be taken and displayed on the front mounted video monitor or LCD screen. Route travel information would appear on screen along with any carrier initiated prompts such as hold or forward mail entered by the keyboard or downloaded in the office. The piece of mail would then convey onto a delivery receptacle convenient to the carrier. Then the next piece would then automatically convey past the reader where the same process would be initiated. At this time the computer would compare the new bar code with the previous bar code. If they are the same, indicating that both pieces belong to the same address, the new piece would automatically convey through to the receiving tray to join the first piece. The new address image would also be displayed on the monitor with the first image. This process would be repeated until a piece of mail came on which the bar code did not match the previous bar coded addresses. Then the conveying process would stop with all matching pieces displayed on the monitor and available to the carrier in the delivery tray. In the case that mail had inadvertently been turned backward or for whatever reason the bar code could not be read these pieces would convey through and the address would be displayed on the monitor or blank spaces would be shown on the monitor for the carrier to peruse and possibly manually sort. In the normal event that all bar codes are readable, the carrier would review the images on the monitor to ascertain that all pieces of mail were correct for delivery to that address. The carrier would remove any pieces which were not correct and deliver that batch to the address indicated. When mail pieces are removed from the delivery receptacle, the same process would automatically be repeated again, having been signaled by a sensor that the delivery receptacle is empty. The machine would also have a manual switch to operate the mail conveying system to help clear jams.

-   -   1. Remove machine from recharge and storage shelf.     -   2. This station may also optionally be used to upload and         download information into and out of machine     -   3. Install machine in convenient location in delivery vehicle.         Plug in power cord.     -   4. Machine could optionally be self-contained and not require         power from vehicle.     -   5. Power up machine and fill receiving receptacle with DPS mail.     -   6. Start machine and machine shuttles first piece of mail past         image viewing and bar code reading device to delivery         receptacle. Image of address is displayed on the monitor and bar         code is read and temporarily stored in computer memory. The next         piece of mail is automatically shuttled through the same         process. The computer compares the new bar code with the bar         code on the previous piece of mail. If the bar codes match,         indicating that the addresses are the same, this piece of mail         is also sent to the delivery tray. Then the next piece of mail         is shuttled past the image viewer and bar code scanner,         repeating the process until a bar code which does not match the         previous bar codes is found which will indicate a new address.         At this time the process is stopped and all processed mail         pieces images are on monitor and all addresses which are the         same being in the delivery receptacle and waiting pick up by the         delivery carrier.     -   7. The machine may also optionally be equipped with a GPS         feature or a route description to prompt carrier for direction         of travel and which streets to follow. This would be especially         helpful for new carriers and substitute carriers.     -   8. The machine may also be optionally be equipped with prompts         to inform carrier when to refill the receiving receptacle or         when not to deliver particular mail.     -   9. The delivery carrier checks the display monitor to affirm         that all mail in the delivery receptacle is deliverable to the         delivery address. The carrier removes the batch of mail from the         delivery receptacle and if necessary, removes any         non-deliverable mail before delivery to the customers mail         receptacle.     -   10. The delivery carrier may also optionally enter information         via keyboard to make notations for on-screen prompts to inform         the carrier of non-deliverable mail, such as vacant houses,         forwarding mail, holding mail, vicious dogs, etc.     -   11. The process described in section 6 is repeated by the         machine. The carrier repeats his or her actions until all         deliverable mail is delivered to customers.     -   12. The carrier arrives back at the post office and removes the         machine and the non-deliverable mail from the delivery vehicle.         The machine is returned to the storage shelf. and plugged in to         recharge. The non-deliverable mail is dealt with by the carrier         on a per case basis.     -   13. In the case of intelligent mail bar codes for tracking, it         would also be desirable to have function of the machine store         information read from the mail and download this information         into a combination charging station/computer relay station and         have this information forwarded by the download station.

CONCLUSION, RAMIFICATIONS, AND SCOPE

I have invented a method of presenting consolidated groups or batches of mail of a common address from pre-sorted or D.P.S. Distribution Point Sequence mail or any other machine-readable and address-sorted mail to a mail carrier for delivery to said common address. A machine which consolidates the mail for each separate delivery address into a single stack for delivery to said address without the necessity to finger through and examine each individual piece before delivery to a single address.

It may be observed that many embodiments of a machine which will consolidate mail into batches for the carrier to deliver may be manufactured. A partial list of examples follows. The following may be changed or deleted from machine and machine will still serve basic function.

-   -   1. No downward pressure arm. Gravity would work or a weight         could be substituted.     -   2. No internal power supply. Machine could be made to function         with only external power.     -   3. No 110 AC cord and transformer. It may not be deemed         necessary to have machine operational for in-office casing         operations.     -   4. No GPS or geographical route travel function.     -   5. No external wireless bar code scanner. Post office already         has existing bar code scanners.     -   6. A different type of mail conveying system, may be used and         machine would still function the same.     -   7. No low or no mail sensor in the receiving tray.     -   8. No upload or download ports. It may be deemed unnecessary to         upload or download information from microprocessor.     -   9. No keyboard for carrier input of information.     -   10. Although I consider the monitor to be necessary for the         carrier to check for mistakes before delivery and not have to         finger through the mail to do so, a basic functioning machine         could be built with no monitor.     -   11. No cooling and dust exhausting fans.     -   12. No hinged access provisions.     -   13. No 12 volt vehicle power cord. Machine could be made to         operate on only the rechargeable internal power source.         Thus the scope of the invention should be determined by the         appended claims and their legal equivalents, rather than by the         examples given. 

1. A machine for presenting mail to delivery carrier for each delivery address from presorted mail pieces comprising. a. a chassis means for affixment of components. b. a cover means for protection of said components. c. a monitor means for visually affirming addresses on said mail pieces. d. a means for a receiving receptacle providing storage for the mail pieces to be processed. e. a conveying means for moving the mail pieces through said machine. f. a means of capturing images of said addresses of the mail pieces conveyed through said machine. g. a means of reading a bar code on the mail pieces conveyed through the machine. h. a means for a microprocessor operatively connected to said bar code means and to said conveying means and to said image capturing means and to said monitoring means to enable operation of the machine. i. a power source means to enable operation of the machine. j. a delivery receptacle means for removal of said processed mail by the carrier.
 2. A machine for presenting mail to delivery carrier in accordance with claim 1 further comprising means for storing a database containing delivery information.
 3. A machine for presenting mail to delivery carrier in accordance with claim 2 with further comprising means of input of data from an external source.
 4. A machine for presenting mail to delivery carrier in accordance with claim 3 with further comprising means of displaying on the monitoring means customers names and addresses and delivery instructions and mail route line of travel directions.
 5. A machine for presenting mail to delivery carrier in accordance with claim 2 further comprising a keyboard means for carrier input of information and data relevant to each delivery address for display on the monitor means.
 6. A machine for presenting mail to delivery carrier in accordance with claim 4 with a keyboard means for carrier input of information and data relevant to each delivery address. whereby a delivery carrier can more easily ascertain addresses of mail to be delivered. whereby a delivery carrier can deliver mail with less physical handling of mail to be delivered. whereby a delivery carrier can deliver mail more efficiently, more accurately, more safely, more comfortably, and use less fuel per delivery.
 7. A machine for presenting mail to delivery carrier for each delivery address from presorted mail pieces comprising. a. a chassis means for affixment of components. b. a cover means for protection of said components. c. a monitor means for visually affirming addresses on said mail pieces. d. a means for a receiving receptacle providing storage for the mail pieces to be processed. e. a conveying means for moving the mail pieces through said machine. f. a device for reading bar code and capturing images of said addresses of the mail pieces conveyed through said machine. g. a means for a microprocessor operatively connected to said bar code means and to said conveying means and to said image capturing means and to said monitoring means to enable operation of the machine. h. a power source means to enable operation of the machine. i. a delivery receptacle means for removal of said processed mail by the carrier.
 8. A machine for presenting mail to delivery carrier in accordance with claim 7 further comprising means for storing a database containing delivery information.
 9. A machine for presenting mail to delivery carrier in accordance with claim 8 with further comprising means of input of data from an external source.
 10. A machine for presenting mail to delivery carrier in accordance with claim 9 with further comprising means of displaying on the monitoring means customers names and addresses and delivery instructions and mail route line of travel directions.
 11. A machine for presenting mail to delivery carrier in accordance with claim 8 further comprising a keyboard means for carrier input of information and data relevant to each delivery address for display on the monitor means.
 12. A machine for presenting mail to delivery carrier in accordance with claim 10 with a keyboard means for carrier input of information and data relevant to each delivery address.
 13. A process for presenting mail to a delivery carrier for each delivery address from presorted mail pieces comprising. a. a first mail piece is conveyed past a bar code reading device to a delivery station a bar code is read and stored in memory. b. a next mail piece is automatically conveyed past said bar code reading device said bar code is read and compared with said first mail piece bar code in said memory and stored if the bar codes match the first mail piece it is conveyed to said delivery station. c. step b. is repeated until a bar code is conveyed which does not match the first mail piece it is stopped and not conveyed to the delivery station. d. the mail piece or mail pieces in the delivery station all have the same bar code and are removed for delivery. e. when mail is removed from the delivery station the above described process is repeated until all mail pieces are delivered. whereby a delivery carrier can more easily ascertain addresses of mail to be delivered. whereby a delivery carrier can deliver mail with less physical handling of mail to be delivered. whereby a delivery carrier can deliver mail more efficiently, more accurately, more safely, more comfortably, and use less fuel per delivery. 